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Grove Crane GMK 5150 Operating Instructions Manual 3302627 – PDF DOWNLOAD
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Description
Grove Crane GMK 5150 Operating Instructions Manual 3302627 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5150 Operating Instructions Manual 3302627 – PDF DOWNLOAD
Language : English
Pages : 1010
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 5150 Operating Instructions Manual 3302627 – PDF DOWNLOAD
Basic safety instructions:
Intended use:
The GMK5150 truck crane is constructed in accordance with the latest tech- nology and the
recognised safety regulations. Nevertheless, the operator or third parties can still be endangered
and the crane or other property put at risk while using it.
- The truck crane may be modified only with the consent of Manitowoc Crane Group Germany GmbH.
- The GMK5150 truck crane may be used only when it is in perfect technical condition and for its
intended purpose and with due attention paid to safe operation and possible hazards.
Any malfunctions that could impair safety must be eliminated immediately. - The GMK5150 truck crane may only be operated without the corresponding special equipment within the
permitted temperature range; à Technical
data, p. 1 – 7. - The GMK5150 truck crane is designed solely for lifting loads which are within the permitted GMK5150
lifting capacities. The load must be slung as prescribed to a hook block which is positioned
vertically over the load prior to lifting.
Intended use also includes
– observing the entire crane documentation, consisting of the operating manual(s), the lifting
capacity table, the outrigger pressure table and the safety manual
– adhering to the inspection and maintenance requirements specified in the maintenance manual.
- The GMK5150 may only be operated with parts of equipment which approved by Manitowoc Crane Group
Germany GmbH and which are labelled with the serial number of the GMK5150. - The manufacturer is not liable for any damage caused by improper or unau- thorized use of the
GMK5150 truck crane. The user shall take on full responsibility for any such use.
TABLE OF CONTENTS:
Grove Crane GMK 5150 Operating Instructions Manual 3302627 – PDF DOWNLOAD
Additional pages ............................................................................. 25 Installing/removing the outrigger beams................................................... 3 Driving with a rigged crane............................................................... 23 CCS – Datalogger.......................................................................... 25 Additional menu and program........................................................... 25 CCS display............................................................................... 31 Menu changes.......................................................................... 31 Reduction of slewing speed – can be switched on and off................................... 35 Dimensions and weights of removable parts................................................. 39 Main boom............................................................................. 39 Possible reeving methods on the main boom................................................. 41 With 6 head sheaves................................................................... 41 With 8 head sheaves................................................................... 44 With 9 head sheaves................................................................... 48 Outrigger spans........................................................................... 49 1 Overview.................................................................................... 55 1.1 Accidents............................................................................. 55 1.2 Branch offices........................................................................ 57 1.2.1 Manitowoc Crane Care............................................................ 57 1.2.2 Dealer list..................................................................... 57 1.3 Warranty specifications............................................................... 57 1.4 Terms used............................................................................ 58 1.5 Technical data........................................................................ 61 1.5.1 Maximum lifting capacity (DIN/ISO/EN)........................................... 61 1.5.2 Maximum lifting capacity (ASME B 30.5).......................................... 61 1.5.3 Dimensions and weights of the truck crane, axle loads........................... 62 Dimensions........................................................................ 63 Weight and axleloads............................................................. 63 1.5.4 Dimensions and weights of removable parts....................................... 64 Spare wheel....................................................................... 64 Outrigger......................................................................... 64 Hook blocks and hook tackle....................................................... 64 Auxiliary hoist................................................................... 65 Counterweight parts.............................................................. 65 1.5.5 Carrier......................................................................... 66 Engine............................................................................ 66 Transmission...................................................................... 66 Transfer case..................................................................... 66 Axle lines........................................................................ 66 Steering.......................................................................... 66 Tyres............................................................................. 67 Outrigger......................................................................... 68 Electrical system................................................................. 69 Tool.............................................................................. 69 Towing coupling.................................................................. 69 Driving speeds.................................................................... 69 Climbing ability.................................................................. 69 Turning radii..................................................................... 70 1.5.6 Superstructure.................................................................. 70 Main hoist........................................................................ 70 Auxiliary hoist................................................................... 71 Slewing gear...................................................................... 71 Derricking gear................................................................... 71 Main boom......................................................................... 71 Lattice extension................................................................. 71 Operating speeds.................................................................. 72 1.6 Documentation supplied................................................................ 73 1.6.1 Questions on documentation...................................................... 74 1.7 Notes on the operating manual......................................................... 75 1.7.1 What do the symbols used mean?.................................................. 75 1.7.2 How is the operating manual structured?......................................... 77 Division.......................................................................... 77 Structure of thechapters......................................................... 77 Structure of thepages............................................................ 78 1.7.3 How do I find the information I need?........................................... 79 Cross-references example.......................................................... 80 1.7.4 What information is available for operations planning?.......................... 82 1.8 Conversion table for US measuring units............................................... 83 1.9 Training – Information................................................................ 85 1.10 Identification....................................................................... 86 1.11 EC Declaration of Conformity......................................................... 88 2 Basic safety instructions................................................................... 91 2.1 Intended use.......................................................................... 91 2.1.1 Improper use.................................................................... 92 2.2 Organisational measures............................................................... 93 2.3 Personnel qualifications.............................................................. 95 2.4 Safety instructions for driving the truck crane....................................... 97 2.5 Safety instructions for crane operation............................................... 99 2.6 Instructions on transporting persons.................................................. 103 Equipment for lifting persons......................................................... 103 Personnel............................................................................. 104 Operation............................................................................. 104 Truck crane........................................................................... 105 3 Operating elements for driving.............................................................. 109 3.1 Overview of the operating elements.................................................... 109 3.1.1 Exterior of the truck crane..................................................... 110 3.1.2 Driver's cab.................................................................... 114 Front overview.................................................................... 114 Rear overview..................................................................... 116 Behind the cover................................................................. 117 3.1.3 Steering column/steering wheel.................................................. 119 3.1.4 Instrument panel................................................................ 121 Left/right........................................................................ 121 Middle............................................................................ 122 3.1.5 Transmission operating elements................................................. 124 3.1.6 On-board computer............................................................... 125 3.1.7 Tachograph, on-board computer time correction................................... 126 3.1.8 Heating and air-conditioning system............................................. 127 Standard.......................................................................... 127 Auxiliary water heating system.................................................. 128 Auxiliary air heater............................................................. 129 3.1.9 CCS control unit................................................................ 130 3.1.10 CCS display – Start menu....................................................... 131 3.1.11 CCS – Overview menu groups..................................................... 132 Carrier menu group................................................................ 134 Suspension/level adjustment menu................................................. 135 Driving menu..................................................................... 136 Settings menu group............................................................... 137 Menu for setting the display brightness anddate/time............................. 138 Switch units menu................................................................. 139 Information menu group............................................................ 140 Operating hours menu............................................................. 141 Engine/transmission error menu................................................... 142 Crane operation error menu....................................................... 143 Operating additional equipment.................................................... 144 Emergency operation............................................................... 145 3.1.12 Outriggers control units....................................................... 146 3.2 Brief description of the operating elements........................................... 147 3.2.1 Definition of direction references.............................................. 147 Basic rule........................................................................ 147 Switches and buttons............................................................. 148 3.2.2 General rules for buttons and symbols on the display............................ 148 3.2.3 Crane control CCS............................................................... 149 3.2.4 Engine.......................................................................... 154 Steering column................................................................... 154 On the steering wheel............................................................. 154 Instrument panel.................................................................. 155 3.2.5 AdBlue system................................................................... 156 Instrument panel.................................................................. 156 CCS display....................................................................... 157 3.2.6 Battery master switch........................................................... 157 3.2.7 Electrical system............................................................... 158 3.2.8 Transmission.................................................................... 159 Transmission control unit......................................................... 159 Display driving mode.............................................................. 161 3.2.9 Reverse camera.................................................................. 162 3.2.10 BirdView system 270 ........................................................... 163 3.2.11 Transfer case.................................................................. 165 3.2.12 Final drive.................................................................... 166 3.2.13 Brakes......................................................................... 168 Service brake..................................................................... 168 Parking brake..................................................................... 168 Additional brakes................................................................. 169 3.2.14 Steering / separate steering................................................... 170 Instrument panel.................................................................. 170 CCS display....................................................................... 172 3.2.15 Suspension..................................................................... 174 CCS display....................................................................... 174 Outriggers control units.......................................................... 174 3.2.16 Lighting/windscreen wipers/horn................................................ 175 Steering column................................................................... 175 Steering wheel.................................................................... 175 Instrument panel.................................................................. 175 CCS display....................................................................... 177 Roof.............................................................................. 177 3.2.17 Level adjustment system........................................................ 178 3.2.18 Tachograph/speedometer......................................................... 180 Tachograph........................................................................ 180 Speedometer....................................................................... 180 3.2.19 Diagnostics.................................................................... 181 3.2.20 On-board computer.............................................................. 182 3.2.21 Push-up roof................................................................... 183 3.2.22 Windows and doors.............................................................. 184 Window winder..................................................................... 184 Doors............................................................................. 185 3.2.23 Front flap..................................................................... 186 4 Starting/switching off the engine – for driving............................................. 189 4.1 Starting the engine from the driver's cab............................................. 189 4.1.1 CHECKLIST: Starting the engine.................................................. 189 4.1.2 CHECKLIST: At low temperatures.................................................. 192 4.1.3 Ladders......................................................................... 193 Folding ladder.................................................................... 194 4.1.4 Refuelling...................................................................... 195 Fuel tank......................................................................... 195 AdBlue tank....................................................................... 197 4.1.5 Checks before starting the engine............................................... 198 At the hydraulic tank............................................................. 198 Battery master switch............................................................. 199 Checking the hand-held control.................................................... 199 4.1.6 Switching on the ignition....................................................... 199 4.1.7 Lamp test/equalisation of the switching states.................................. 200 Lamp test......................................................................... 200 Alignment of theswitching statuses............................................... 200 4.1.8 Display brightness.............................................................. 201 4.1.9 Start the engine................................................................ 202 4.1.10 Inspections after starting the engine.......................................... 204 Main menu and on-board computer display........................................... 204 Instrument panel.................................................................. 205 4.1.11 Adjust idling speed............................................................ 207 4.2 Switching off the engine.............................................................. 209 4.2.1 At the ignition lock and with the outrigger control units....................... 209 After turning off................................................................ 209 4.2.2 With emergency stop switches.................................................... 210 Resetting the emergency stop switch............................................... 210 4.3 Air intake inhibitor.................................................................. 211 Releasing the air intake inhibitor.................................................... 211 5 Driving mode................................................................................ 215 5.1 Before driving........................................................................ 215 5.1.1 CHECKLIST: Checks before on-road driving........................................ 215 5.1.2 Checking the condition of the truck crane....................................... 221 Electrical system................................................................. 221 Adjust the mirrors................................................................ 221 Warning plates for vehicle width.................................................. 222 Displaying vehicle height......................................................... 223 Supply pressure................................................................... 224 Parking brake..................................................................... 225 5.1.3 Adjusting the seats and steering column......................................... 227 Adjusting the driver's seat...................................................... 227 Adjusting the passenger's seat................................................... 228 Steering column, adjusting....................................................... 229 5.1.4 Switching the suspension on/off................................................. 230 Open menu......................................................................... 230 Switching the suspension on...................................................... 231 Switching off the suspension..................................................... 231 5.1.5 Setting the tachograph.......................................................... 232 Prerequisites..................................................................... 232 In the event of malfunctions...................................................... 232 Setting the tachograph........................................................... 233 5.1.6 Entering the time/date.......................................................... 237 5.1.7 Displaying and resetting operating hours........................................ 238 5.2 Operating the transmission............................................................ 239 5.2.1 Switching on.................................................................... 239 5.2.2 Switching the transmission to the neutral position.............................. 240 5.2.3 Selecting the direction of travel and starting gear............................. 241 Selecting the driving direction.................................................. 241 Selecting the starting gear .................................................... 242 5.2.4 Changing the operating mode..................................................... 243 Changing to automatic mode........................................................ 243 Changing to manual mode........................................................... 243 5.2.5 Starting........................................................................ 244 5.2.6 Driving and changing gears...................................................... 245 In automatic operating mode....................................................... 245 In manual operating mode.......................................................... 246 5.2.7 Changing the driving direction.................................................. 247 5.2.8 Stopping........................................................................ 247 Stopping for a long period of time............................................... 247 5.2.9 On the roller type dynamometer.................................................. 248 5.2.10 Preheating transmission........................................................ 248 5.3 Driving and turning off the truck crane............................................... 249 5.3.1 Checks while driving............................................................ 249 Immediately after you start to move............................................... 249 While driving..................................................................... 251 5.3.2 Cruise control.................................................................. 252 Switching on...................................................................... 252 Switching off..................................................................... 253 5.3.3 Temposet........................................................................ 253 Switching on...................................................................... 253 Switching off..................................................................... 254 5.3.4 Driving downhill................................................................ 255 Starting.......................................................................... 255 Inspections when driving downhill................................................ 256 Downshifting...................................................................... 256 Additional brakes................................................................. 257 5.3.5 Driving uphill.................................................................. 259 Starting.......................................................................... 259 Driving........................................................................... 259 5.3.6 Warning or malfunction messages on the instrument panel......................... 260 Meaning of thelamps.............................................................. 260 5.3.7 Messages on the on-board computer display....................................... 261 5.3.8 Indicator lights in the on-board computer display............................... 263 5.3.9 Overriding the torque reduction................................................. 265 5.3.10 Warnings in the start menu..................................................... 266 5.3.11 Switching the truck crane off.................................................. 267 Secure it against rolling away.................................................... 268 When stationary for more than 8hours............................................. 269 5.3.12 Fold-up berth.................................................................. 270 5.4 Off-road driving...................................................................... 271 Adjustments to the transmission....................................................... 271 Connections........................................................................... 271 Changing the vehicle level............................................................ 271 Rocking the vehicle free and towing................................................... 271 5.4.1 Transfer case – switching the off-road gear on/off.............................. 272 Neutral position.................................................................. 272 5.4.2 Longitudinal and transverse differential locks.................................. 273 5.4.3 Operating the level adjustment system........................................... 275 Open menu......................................................................... 275 Setting the on-road level........................................................ 276 Pre-selecting suspension struts.................................................. 276 Changing the vehicle level........................................................ 277 Viewing the current inclination................................................... 277 Exiting the menu................................................................. 278 5.4.4 Freeing an immobilized truck crane.............................................. 279 Rocking the truck crane free..................................................... 279 Towing free to thefront......................................................... 280 Towing free in reverse gear...................................................... 280 5.5 Separate steering..................................................................... 281 5.5.1 Switching to separate steering.................................................. 282 5.5.2 Switching to normal steering mode............................................... 285 5.5.3 Switching units of measure...................................................... 286 5.6 Heating and air-conditioning system................................................... 287 5.6.1 Standard heating system......................................................... 287 Switching on...................................................................... 287 Heating........................................................................... 287 Air distribution.................................................................. 288 Examples.......................................................................... 289 Switching off..................................................................... 289 5.6.2 Air-conditioning system......................................................... 290 Information....................................................................... 290 Switching on/off.................................................................. 290 Cooling........................................................................... 291 Drying............................................................................ 291 5.6.3 Auxiliary water heating system.................................................. 293 Preheating theengine............................................................ 293 Preheating the driver's cab...................................................... 294 Switching on...................................................................... 294 Adjusting thedateand time....................................................... 296 Storing the heating start........................................................ 297 5.6.4 Auxiliary air heater............................................................ 299 Switching on...................................................................... 299 Setting the heating level........................................................ 300 Setting the day and time......................................................... 301 Setting the preselection time..................................................... 301 Deleting preselection times....................................................... 303 Switching off..................................................................... 303 5.7 Towing a trailer...................................................................... 305 Effects on the axleloads............................................................. 305 Coupling thetrailer................................................................. 306 Connecting the supply lines.......................................................... 307 Removing supplylines............................................................... 308 Uncoupling thetrailer............................................................... 308 Checking the braking force............................................................ 310 6 Driving modes............................................................................... 313 6.1 Driving modes......................................................................... 313 Information on the axle loads......................................................... 313 6.1.1 How to use the tables:......................................................... 314 6.1.2 Table for a maximum axle load of 12 t (26,500 lbs).............................. 315 385/95 R25 tyres.................................................................. 315 445/95 R25 tyres.................................................................. 316 525/80 R25 tyres.................................................................. 317 6.1.3 Maximum permitted speeds with an axle load of over 12 t (26500 lbs)............ 318 6.2 Weighing the truck crane.............................................................. 319 Axle groups........................................................................... 320 Weighing procedure.................................................................... 321 Evaluation............................................................................ 322 6.3 Rigging work for driving with a trailer............................................... 323 6.3.1 Switching on the slewing gear freewheel......................................... 324 6.3.2 Switching on the boom floating position......................................... 325 6.3.3 Switching on boom pre-tensioning................................................ 326 6.3.4 Raising/lowering the 3rd axle line for towing a trailer......................... 327 Lifting........................................................................... 327 Lowering.......................................................................... 327 6.4 Rigging the main boom................................................................. 329 Additional equipment required......................................................... 329 6.4.1 CHECKLIST: removing the main boom............................................... 330 Prerequisites..................................................................... 330 Checklist......................................................................... 330 6.4.2 CHECKLIST: installing the main boom............................................. 333 Prerequisites..................................................................... 333 Checklist......................................................................... 333 6.4.3 Slinging the main boom.......................................................... 336 Marking........................................................................... 336 Installing the lifting gear....................................................... 336 Removing the lifting gear......................................................... 337 6.4.4 Switching the pressure relief on/off............................................ 338 6.4.5 Retracting/fitting the derricking cylinder head pin............................. 339 Retracting the derricking cylinder head axle...................................... 340 Fitting the derricking cylinder head axle......................................... 341 6.4.6 Extending/retracting the boom pivot pin......................................... 342 Before pulling itout............................................................. 342 After pushing it in............................................................... 342 Pulling out the pivot pin......................................................... 343 Pushing the pivotpin in.......................................................... 344 6.4.7 Removing/attaching the clamps................................................... 346 6.4.8 Disconnecting/connecting hydraulics/electrical.................................. 347 Disconnecting..................................................................... 347 Connecting........................................................................ 348 6.4.9 Aligning the connecting points.................................................. 349 6.4.10 Securing/releasing the derricking cylinder..................................... 350 6.4.11 Transporting the main boom..................................................... 350 6.4.12 Inspections after main boom mounting........................................... 351 6.5 Installing/removing the auxiliary hoist............................................... 353 6.5.1 Slinging the auxiliary hoist.................................................... 353 6.5.2 CHECKLIST: Installing the auxiliary hoist....................................... 354 6.5.3 CHECKLIST: Removing the auxiliary hoist......................................... 355 6.5.4 Making/breaking the connection between the auxiliary hoist and the turntable.... 356 6.5.5 Establishing/disconnecting the hydraulic connection............................. 357 6.5.6 Establishing/disconnecting the electrical connection............................ 358 6.5.7 Making/breaking the connection to the central lubrication....................... 359 6.5.8 Transporting the auxiliary hoist................................................ 360 6.5.9 Check that the auxiliary hoist is functioning properly.......................... 361 Slewing direction................................................................. 361 Slewing indicator................................................................. 361 7 Transport................................................................................... 365 7.1 Transport with transport vehicle...................................................... 365 7.1.1 CHECKLIST: Checks before transport.............................................. 366 7.1.2 Drive the truck crane on to the transport vehicle............................... 368 Driving on........................................................................ 369 Lashing........................................................................... 369 7.2 Transport by ship..................................................................... 370 8 Malfunctions in driving mode................................................................ 373 8.1 Emergency stop switches............................................................... 373 8.2 What to do when a malfunction occurs in road traffic.................................. 375 8.3 Towing away the truck crane........................................................... 377 8.3.1 Towing after engine/transmission damage......................................... 378 Compressed-air supply............................................................. 378 Electric power supply............................................................. 378 On the transmission............................................................... 379 Axle drives....................................................................... 379 Parking brake..................................................................... 380 Towing the truck crane out of the danger area..................................... 381 Longer towing distances........................................................... 381 8.3.2 Tow starting.................................................................... 381 8.4 Other emergency operations............................................................ 383 8.4.1 Externally starting the truck crane............................................. 383 8.4.2 Battery charger................................................................. 384 Prerequisites..................................................................... 384 8.5 Wheels and tyres...................................................................... 385 8.5.1 Wheel change.................................................................... 385 Removing a damaged wheel.......................................................... 386 On the spare wheel holder......................................................... 386 Mounting a wheel.................................................................. 387 8.5.2 Inflating the tyres yourself.................................................... 389 Connecting the filling hose....................................................... 389 Inflating the tyres............................................................... 390 Remove the fillinghose.......................................................... 390 8.6 Tilting/lowering the driver's cab..................................................... 391 8.6.1 Prerequisites and information on tilting........................................ 391 8.6.2 Tilting/lowering the driver's cab............................................... 392 Operating the hand pump........................................................... 392 Tilting the driver'scab.......................................................... 393 Lowering the driver's cab........................................................ 394 8.7 Fuses on the carrier.................................................................. 397 Information on replacing fuses...................................................... 397 8.7.1 Fuses in the driver's cab....................................................... 398 8.7.2 Fuses in the battery box........................................................ 404 8.8 Troubleshooting....................................................................... 405 8.8.1 Malfunctions on the engine...................................................... 405 When operating with the dual tank................................................. 407 8.8.2 Faults on the Adblue system..................................................... 407 8.8.3 Malfunctions of the differential locks.......................................... 408 8.8.4 Malfunctions in the transmission................................................ 409 8.8.5 Malfunctions of the steering.................................................... 410 8.8.6 Malfunctions of the service brake............................................... 411 8.8.7 Malfunctions on the suspension.................................................. 412 8.8.8 Malfunctions of the level adjustment system..................................... 412 8.8.9 Malfunctions in the hydraulic system/hydraulic oil cooler....................... 412 8.9 CCS warning/error message............................................................. 413 Symbols in the display area........................................................... 413 8.9.1 Engine/transmission error menu.................................................. 417 Open menu......................................................................... 417 Exiting the menu.................................................................. 417 8.10 Procedure during malfunctions........................................................ 419 8.10.1 Procedure during engine malfunctions........................................... 419 8.10.2 Procedure during transmission malfunctions..................................... 420 9 Operating elements for crane operation...................................................... 425 9.1 Overview of the operating elements.................................................... 425 9.1.1 Exterior of the truck crane..................................................... 426 9.1.2 Crane cab....................................................................... 430 Side panel........................................................................ 432 Crane cab, rear................................................................... 434 9.1.3 Control panels.................................................................. 436 Left.............................................................................. 436 Right............................................................................. 437 9.1.4 Control lever configuration..................................................... 438 Version 1......................................................................... 438 Version 2......................................................................... 439 9.1.5 CCS control unit................................................................ 440 9.1.6 CCS – Start menu................................................................ 443 9.1.7 CCS – Overview menu groups...................................................... 444 Superstructure menu group......................................................... 448 Superstructure lock sub-menu.................................................... 449 Counterweight menu................................................................ 450 Outrigger menu.................................................................... 451 Outrigger support beam menu...................................................... 453 Outrigger cylinders menu......................................................... 454 Menu group Teleautomation......................................................... 456 Telescoping full automation menu................................................. 457 Telescoping semi- automation menu................................................ 458 Manual telescoping menu.......................................................... 459 Main boom configuration menu...................................................... 460 Active working range limiter menu group........................................... 461 Overall height menu.............................................................. 462 Working radius menu............................................................... 463 Slewing angle menu................................................................ 464 Hoist rope travel limitation menu................................................. 465 Information menugroup............................................................ 466 Hydraulic pressure and fuel consumption menu...................................... 467 Engine/Driving menu group......................................................... 469 Driving mode menu................................................................ 470 Economy mode menu................................................................. 472 Remote control menu............................................................... 473 Heating/air-conditioning menu..................................................... 474 Spotlights menu................................................................... 475 Telescoping emergency program menu group......................................... 476 Unknown telescoping menu......................................................... 477 Telescoping emergency program menu............................................... 478 Settings menu group............................................................... 479 Crane cab menu.................................................................... 480 Menu for setting the display brightness and date/ time............................ 481 Switch units menu................................................................. 482 Set control lever characteristic curve menu....................................... 483 Power unit speeds menu.......................................................... 484 Information menu group............................................................ 485 Operating hours menu.............................................................. 486 Engine/transmission error menu.................................................... 487 Crane operation error menu........................................................ 488 Program version menu.............................................................. 489 Operating additional equipment.................................................... 490 9.1.8 RCL control unit................................................................ 491 9.1.9 RCL – menu groups............................................................... 494 Enter rigging mode menu........................................................ 496 Monitoring menu.................................................................. 497 Lifting capacity table menu..................................................... 498 9.1.10 Hand-held control.............................................................. 499 9.1.11 Outriggers control units....................................................... 500 Button............................................................................ 500 Outrigger button.................................................................. 501 Inclination and outrigger pressure display........................................ 502 Raise axle display................................................................ 503 9.2 Brief description of the operating elements........................................... 505 9.2.1 Definition of direction references.............................................. 505 Basic rule........................................................................ 505 Switches.......................................................................... 505 9.2.2 General rules for buttons and symbols on the display............................ 506 9.2.3 Crane control CCS............................................................... 507 9.2.4 Engine.......................................................................... 514 Side panel....................................................................... 514 CCS display....................................................................... 514 Economy mode menu................................................................. 515 Left control lever................................................................ 515 9.2.5 AdBlue system................................................................... 516 CCS display....................................................................... 516 9.2.6 Seat contact switch and dead man's switch....................................... 517 9.2.7 Outrigger....................................................................... 519 Right-hand control panel.......................................................... 519 Left-hand controlpanel........................................................... 519 In the Outrigger menu............................................................ 520 At the outrigger control units.................................................... 523 9.2.8 Inclination indicators.......................................................... 525 9.2.9 Raise axle...................................................................... 526 Outriggers control units.......................................................... 526 CCS display....................................................................... 527 9.2.10 Outrigger pressure displays.................................................... 528 Outrigger submenu................................................................ 528 Outriggers controlunits......................................................... 528 9.2.11 Anemometer displays............................................................ 528 9.2.12 Counterweight menu............................................................. 530 Counterweight submenu............................................................ 530 9.2.13 Main hoist..................................................................... 534 Control panels.................................................................... 534 CCS display....................................................................... 534 9.2.14 Auxiliary hoist................................................................ 536 Control panels.................................................................... 536 CCS display....................................................................... 536 9.2.15 Slewing gear................................................................... 538 Control panels.................................................................... 538 CCS display....................................................................... 539 9.2.16 Derricking gear................................................................ 540 Control panels.................................................................... 540 CCS display....................................................................... 541 9.2.17 Telescoping mechanism.......................................................... 542 Control panels.................................................................... 542 CCS display....................................................................... 542 Telescoping full automation menu.................................................. 543 Telescoping semi- automation menu................................................. 544 Manual telescoping menu........................................................... 546 Main boom configuration menu...................................................... 549 9.2.18 Hydraulic system............................................................... 550 9.2.19 Superstructure lock/house lock menu............................................ 551 Superstructure lock.............................................................. 551 Houselock......................................................................... 552 9.2.20 Remote control................................................................. 553 9.2.21 Rated capacity limiter (RCL)................................................... 554 Control unit control console RCL.................................................. 554 Display RCL....................................................................... 555 Enter rigging mode menu........................................................... 556 Monitoring menu................................................................... 560 Lifting capacity tables menu...................................................... 564 RCL override – version A.......................................................... 565 RCL override – Version B.......................................................... 566 9.2.22 Electrical system.............................................................. 567 9.2.23 Lighting, windscreen wiper/washing system...................................... 568 Lighting.......................................................................... 568 Windscreen wiper/washing system.................................................. 570 9.2.24 Hand-held control.............................................................. 572 Sockets for hand-held control..................................................... 572 Engine control panel.............................................................. 573 Horn.............................................................................. 573 Outriggers control panel......................................................... 574 9.2.25 Windows and doors.............................................................. 576 Windows........................................................................... 576 Rear window....................................................................... 576 Crane cab door.................................................................... 577 9.2.26 Diagnostics.................................................................... 578 9.3 Short description of the operating elements – driving from the crane cab.............. 579 9.3.1 Driving mode menu............................................................... 579 9.3.2 Transmission.................................................................... 580 9.3.3 Final drive..................................................................... 581 9.3.4 Brakes.......................................................................... 582 CCS display....................................................................... 582 Side panel from above............................................................. 583 9.3.5 Steering........................................................................ 584 CCS display....................................................................... 584 Separate steering................................................................. 585 Control panels.................................................................... 587 10 Starting/switching off the engine – for crane operation.................................... 591 10.1 When starting the engine for the first time in the day............................... 591 10.2 Starting the engine – from the crane cab............................................. 593 10.2.1 Check the fuel level and AdBlue level.......................................... 593 Fuel.............................................................................. 593 AdBlue............................................................................ 593 10.2.2 Checks before starting the engine.............................................. 594 Checks on thecarrier............................................................ 594 Checking the hand-held control.................................................... 594 At the hydraulic tank............................................................. 594 10.2.3 Switching on the ignition...................................................... 595 10.2.4 Alignment of the switching statuses............................................ 596 Alignment of theswitching statuses............................................... 596 10.2.5 Display – setting the brightness............................................... 597 10.2.6 Start the engine............................................................... 598 10.2.7 Inspections after starting the engine.......................................... 599 10.2.8 Adjust idling speed............................................................ 600 10.3 Starting the engine – with the hand-held control..................................... 601 10.4 Switching off the engine............................................................. 603 10.4.1 At the ignition lock and with hand-held control................................ 603 After turning off................................................................ 603 10.4.2 With the idling button......................................................... 603 10.4.3 Using the emergency stop switches.............................................. 604 Resetting the emergency stop switch............................................... 604 11 Crane operation............................................................................ 607 11.1 Before operating the crane........................................................... 607 11.1.1 CHECKLIST: Checks before operating the crane................................... 607 11.1.2 Checking the condition of the truck crane...................................... 611 Fuel tank auxiliary heater........................................................ 611 Visual inspection................................................................. 611 Checking the position of the hoist ropes.......................................... 612 Checking the electrical system.................................................... 613 11.1.3 Adjusting the crane cab seat and front control panel........................... 614 Crane cab seat.................................................................... 614 Front panel....................................................................... 615 11.1.4 Checking the safety equipment.................................................. 616 Rated capacity limiter............................................................ 616 Lifting limit switch............................................................. 616 Emergency stop switches........................................................... 617 Seat contact switch.............................................................. 618 11.1.5 Earthing the load.............................................................. 619 11.1.6 Preheating the hydraulic oil................................................... 620 Prerequisites..................................................................... 620 Preheating........................................................................ 620 11.1.7 Locking/unlocking the superstructure........................................... 621 Locking points.................................................................... 621 Locking the superstructure....................................................... 622 Unlocking the superstructure..................................................... 622 11.1.8 Switching the houselock on/off................................................. 623 Switching on the houselock....................................................... 623 Switching off the houselock...................................................... 625 11.2 Operation of the rated capacity limiter.............................................. 627 11.2.1 Switch on the RCL.............................................................. 628 Switching on...................................................................... 628 Brightness of thedisplays........................................................ 630 Temperature on the display........................................................ 630 11.2.2 Enter rigging mode............................................................. 631 Entering individual components.................................................... 632 Entering the RCLcode............................................................ 637 Enter the reeving................................................................ 638 Accepting the rigging mode........................................................ 638 11.2.3 Checks before operating the crane.............................................. 640 Open menu......................................................................... 640 Checks............................................................................ 640 11.2.4 Displays during crane operation................................................ 643 11.2.5 RCL early warning.............................................................. 646 11.2.6 RCL shutdown................................................................... 646 Shutdown due tooverload.......................................................... 646 11.2.7 Display in the event of errors................................................. 648 11.2.8 RCL override – version A....................................................... 649 Overview status display........................................................... 649 When rigging...................................................................... 650 To raise the boom................................................................. 651 In emergencies.................................................................... 652 11.2.9 RCL override – version B....................................................... 653 11.2.10 Displaying the lifting capacity tables........................................ 654 11.2.11 Setting the time/date......................................................... 656 11.3 Crane operation with main boom....................................................... 657 11.3.1 Checks during crane operation.................................................. 657 Horizontal alignment.............................................................. 657 Safe distances................................................................... 657 Checking the windspeed........................................................... 658 11.3.2 Permissible slewing ranges and working positions............................... 659 360 slewing range................................................................ 659 Working position 0 to the rear................................................... 659 180 to the front rigging position................................................ 659 11.3.3 Main hoist..................................................................... 661 Switching on the main hoist....................................................... 662 Lifting and lowering............................................................. 662 Maximum permissible hoist rope speed.............................................. 662 Switching off the main hoist..................................................... 663 11.3.4 Auxiliary hoist................................................................ 665 Switching on the auxiliary hoist................................................. 665 Lifting and lowering............................................................. 666 Maximum permissible hoist rope speed.............................................. 666 Switching off the auxiliary hoist................................................ 667 11.3.5 Lifting limit switch and lowering limit switch................................. 669 Lifting limit switch.............................................................. 669 Lowering limit switch............................................................. 671 11.3.6 Derricking gear................................................................ 672 Switching on the derricking gear................................................. 672 Maximum permissible derricking speed.............................................. 672 Raising and lowering.............................................................. 673 Re-enable raising function........................................................ 674 Switching off the derricking gear................................................. 674 11.3.7 Telescoping mechanism.......................................................... 676 Overview.......................................................................... 677 Telescoping process............................................................... 678 Assignment fordisplay............................................................ 680 Fixed length, intermediate length, telescoping length............................ 681 Telescoping....................................................................... 682 Telescoping sequence............................................................. 682 Checks before starting work...................................................... 683 Switching on thetelescoping mechanism............................................ 684 Function of the control lever..................................................... 684 Switching off thetelescoping mechanism........................................... 686 Manual telescoping............................................................... 687 Checking the initial position..................................................... 687 Unlocking the telescoping cylinder................................................ 689 Extending/ retracting the telescoping cylinder.................................... 691 Locking the telescoping cylinder.................................................. 692 Unlocking the telescopic section................................................. 693 Telescoping the telescopic section............................................... 694 Locking the telescopic section................................................... 695 Locking the telescopic section for on-road driving............................... 696 Telescoping with semi-automaton................................................... 696 Telescoping with full automation.................................................. 699 Telescoping withmain boom configuration.......................................... 700 11.3.8 High-speed mode................................................................ 701 Derricking gear telescoping mechanism............................................ 701 Hoists............................................................................ 701 11.3.9 Slewing gear................................................................... 703 Switching on the slewing gear.................................................... 703 Releasing the slewing gear brake.................................................. 703 Applying the slewing gear brake................................................... 704 Slewing........................................................................... 704 Releasing locked slewing gear..................................................... 704 Maximum permitted slewing speed................................................... 705 Braking the slewing movement...................................................... 706 Slewing gear freewheel............................................................ 706 Switching off the slewing gear................................................... 707 11.3.10 Possible movement combinations................................................ 708 11.4 Settings and displays for crane operation............................................ 709 11.4.1 Inclining the crane cab........................................................ 709 11.4.2 Adjust idling speed............................................................ 710 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper.................... 710 11.4.4 Limiting the power unit speeds................................................. 711 11.4.5 Economy mode................................................................... 712 Switching on...................................................................... 712 Switch off/exit................................................................... 714 11.4.6 Switching units of measure..................................................... 715 11.4.7 Setting the characteristic curves for the control levers....................... 716 11.4.8 Using the slewable spotlights.................................................. 717 Manually swinging................................................................. 717 Automatic load tracking........................................................... 718 11.4.9 Overriding the torque reduction................................................ 719 11.4.10 Displaying the operating hours................................................ 720 11.4.11 Warnings in the start menu.................................................... 722 Meaning of the symbols............................................................ 722 11.5 Working range limiter................................................................ 726 11.5.1 Viewing current settings....................................................... 727 11.5.2 Opening the working range limiter menu......................................... 727 11.5.3 Entering limit values.......................................................... 730 Overall height.................................................................... 730 Working radius.................................................................... 731 Slewing angle..................................................................... 731 Hoist rope travel limitation...................................................... 732 11.5.4 Entering limit values manually................................................. 733 Limit values...................................................................... 733 11.5.5 Switching monitoring functions on/off.......................................... 735 11.5.6 Shutdown by working range limiter.............................................. 736 11.6 Work break........................................................................... 737 11.6.1 In case of short work breaks................................................... 737 11.6.2 In case of work breaks of more than 8 hours.................................... 738 To secure the truck crane......................................................... 738 11.7 Heating and air-conditioning system.................................................. 739 11.7.1 Standard heating system........................................................ 739 Switching on...................................................................... 739 Heating........................................................................... 739 Air distribution.................................................................. 740 Switching off..................................................................... 740 11.7.2 Air-conditioning system........................................................ 741 Information....................................................................... 741 Switching on/off.................................................................. 741 Cooling, automatic................................................................ 742 Cooling, maximum.................................................................. 742 11.7.3 Auxiliary heater............................................................... 743 Switching on...................................................................... 743 Adjusting the temperature......................................................... 744 Setting the heating start/ heating duration....................................... 744 Switching heating start on/off.................................................... 745 11.8 CraneSTAR system..................................................................... 746 11.8.1 Overview....................................................................... 746 11.8.2 Position of the components..................................................... 746 12 Rigging work............................................................................... 749 12.1 Rigging work checklists for crane operation with the main boom....................... 749 12.1.1 CHECKLIST: Rigging............................................................. 749 12.1.2 CHECKLIST: Unrigging........................................................... 755 12.2 Selecting the suitable site.......................................................... 759 12.2.1 Determining the required load-bearing area..................................... 759 12.2.2 Safe distance from slopes and pits............................................. 762 12.2.3 Earthing the truck crane....................................................... 763 12.2.4 Safe distance from overhead power lines........................................ 764 12.3 Rigging work after driving with a trailer............................................ 767 12.3.1 Switching off the boom floating position....................................... 767 12.3.2 Switching off the slewing gear freewheel....................................... 768 Before slewing.................................................................... 768 12.3.3 Switching off boom pre-tensioning.............................................. 769 12.4 Connecting/disconnecting the hand-held control....................................... 771 12.5 Starting the engine for rigging...................................................... 773 12.5.1 Starting/turning off the engine with the hand-held control..................... 773 Prerequisites..................................................................... 773 Start the engine.................................................................. 774 Switching off theengine.......................................................... 774 12.5.2 Starting/switching off the engine from the outrigger control units............. 775 Prerequisites..................................................................... 775 Start the engine.................................................................. 775 Switching off theengine.......................................................... 775 12.6 Outrigger............................................................................ 777 12.6.1 CHECKLIST: Extending the outriggers............................................ 777 12.6.2 CHECKLIST: Retracting the outriggers........................................... 779 12.6.3 Permissible outrigger spans.................................................... 780 12.6.4 Preparing the truck crane...................................................... 781 Driver's cab...................................................................... 781 Crane cab......................................................................... 781 12.6.5 Setting the spans.............................................................. 783 For on-road driving............................................................... 785 12.6.6 Extending/retracting outrigger beams........................................... 787 From the control units............................................................ 788 From the cranecab................................................................ 789 12.6.7 Moving the outrigger pads into operating/driving position...................... 791 12.6.8 Enlarging the load-bearing area................................................ 793 12.6.9 Extending/retracting supporting cylinders...................................... 794 From the controlunits............................................................ 795 From the cranecab................................................................ 796 12.6.10 Levelling the truck crane on outriggers....................................... 798 Inclination indicators............................................................ 798 Prerequisites..................................................................... 799 Manual alignment................................................................. 800 Automatic alignment............................................................... 801 12.6.11 Levelling the free-on-wheels truck crane...................................... 802 12.6.12 Outrigger pressure display.................................................... 804 12.7 Rigging/unrigging the counterweight.................................................. 805 12.7.1 Information on rigging......................................................... 805 When rigging...................................................................... 806 When unrigging.................................................................... 807 12.7.2 Counterweight sections......................................................... 808 Version 1......................................................................... 808 Version 2......................................................................... 808 Version 3......................................................................... 809 12.7.3 Identification................................................................. 810 12.7.4 Slinging points on the counterweight sections.................................. 811 12.7.5 CHECKLIST: Rigging the counterweight........................................... 813 12.7.6 CHECKLIST: Unrigging the counterweight......................................... 815 12.7.7 Assembling counterweight versions.............................................. 817 Setting down the 2.3 t base plate................................................. 818 Setting down the top counterweight section........................................ 818 Version 1......................................................................... 819 Version 2......................................................................... 827 Version 3......................................................................... 831 12.7.8 Counterweight hoist unit....................................................... 839 Counterweight menu............................................................... 839 Extending/ retracting the lifting cylinders....................................... 840 Automatic moderigging........................................................... 842 Automatic mode unrigging......................................................... 844 Cancel automatic mode............................................................ 845 12.7.9 Removing/installing the counterweight on the turntable......................... 846 Removing.......................................................................... 846 Installing........................................................................ 847 12.7.10 Setting down counterweight for driving the truck crane........................ 848 Version 1 and 3................................................................... 848 Version 2......................................................................... 850 12.7.11 Slewing with the rigged counterweight......................................... 851 12.8 Rigging work on the main boom........................................................ 853 12.8.1 Hook block on the bumper....................................................... 853 Picking up the hook block......................................................... 853 Attaching the hook block.......................................................... 854 12.8.2 Hook block on a separate vehicle............................................... 855 Picking up the hook block........................................................ 856 Setting down the hook block...................................................... 856 12.8.3 Hook block, separable.......................................................... 858 Rigging for on-road driving....................................................... 858 Rigging for crane operation....................................................... 859 12.8.4 Reeving and unreeving the hoist rope........................................... 860 Version A......................................................................... 860 Version B......................................................................... 861 Reeving the hoist rope............................................................ 863 Unreeving hoist rope............................................................. 867 12.8.5 Possible reeving methods on the main boom...................................... 868 With 6 head sheaves............................................................... 868 With 8 head sheaves............................................................... 870 With 9 head sheaves............................................................... 874 12.8.6 Installing/removing the lifting limit switch................................... 875 Installing lifting limit switch................................................... 875 Removing the lifting limit switch................................................. 878 12.8.7 Locking/unlocking the lifting limit switch..................................... 880 Locking........................................................................... 880 Unlocking........................................................................ 880 12.8.8 Anemometer and air traffic control light....................................... 881 Installing........................................................................ 881 Switching the air traffic control light on and off................................ 882 Removing.......................................................................... 882 12.9 Other rigging works.................................................................. 885 12.9.1 Folding the mirrors in and out, and adjusting them............................. 885 12.9.2 Cameras for crane operation.................................................... 886 Camera on mainboom............................................................... 886 Camera on thehoists.............................................................. 888 Camera on the driver's cab........................................................ 888 Operating the camera.............................................................. 889 12.9.3 Railings on the turntable...................................................... 890 12.9.4 Step for the crane cab......................................................... 891 12.9.5 Slinging points for personal protective equipment.............................. 892 13 Driving with a rigged truck crane.......................................................... 895 13.1 Driving path......................................................................... 895 13.2 Permissible rigging modes and axle loads............................................. 896 Axle load table...................................................................... 896 13.2.1 To drive without a load........................................................ 898 13.2.2 To drive with a load........................................................... 899 13.2.3 Axle loads..................................................................... 899 13.3 Before driving the rigged truck crane................................................ 900 13.3.1 Check the tyre pressures and wind speed........................................ 900 13.3.2 Securing the superstructure against slewing.................................... 900 13.3.3 Putting the truck crane on the wheels.......................................... 901 13.4 Driving from the driver's cab........................................................ 903 13.4.1 Preparing to drive............................................................. 903 Transmission...................................................................... 903 Switching on separate steering.................................................... 903 Connections....................................................................... 903 13.4.2 While driving.................................................................. 904 13.4.3 After driving.................................................................. 905 13.5 Driving from the crane cab........................................................... 907 13.5.1 Preparing to drive............................................................. 908 13.5.2 Opening/closing the Driving menu............................................... 908 Opening........................................................................... 908 Crane hydraulic system on/off..................................................... 909 Closing........................................................................... 910 13.5.3 Steering....................................................................... 911 Switching on...................................................................... 911 Steering direction................................................................ 911 Displays when steering............................................................ 912 Separate steering................................................................. 912 Normal steering mode.............................................................. 916 13.5.4 Operating the transmission..................................................... 917 Selecting the transmission mode.................................................. 917 13.5.5 While driving.................................................................. 918 DMand RM transmission mode....................................................... 918 Transmission mode D............................................................... 918 Warning messages.................................................................. 918 13.5.6 Possible connections........................................................... 919 Longitudinal/ transverse differential locks....................................... 919 13.5.7 After driving.................................................................. 921 14 Malfunctions during crane operation........................................................ 925 14.1 Emergency stop switches.............................................................. 925 14.2 What to do when malfunctions occur during crane operation............................ 927 The load can be set down.............................................................. 927 Load cannot be set down............................................................... 927 14.3 Fuses in the crane cab............................................................... 929 Information on replacing fuses...................................................... 929 14.4 Troubleshooting...................................................................... 934 14.4.1 Malfunctions on the engine..................................................... 934 14.4.2 Malfunctions when operating with the hand-held control......................... 934 14.4.3 Malfunctions on the turntable lock............................................. 935 14.4.4 Malfunctions when inclining the crane cab...................................... 935 14.4.5 Malfunctions on the main hoist................................................. 936 14.4.6 Malfunctions in the telescoping mechanism...................................... 937 14.4.7 Malfunctions in the hoist cameras.............................................. 938 14.4.8 Malfunctions in the main boom camera........................................... 938 14.4.9 Malfunctions on the derricking gear............................................ 939 14.4.10 Malfunctions on the slewing gear.............................................. 940 14.4.11 Malfunctions on the counterweight hoist unit.................................. 941 14.4.12 Malfunctions in the hydraulic system/hydraulic oil cooler..................... 942 14.4.13 Malfunctions when driving from the crane cab.................................. 942 14.4.14 Malfunctions of the outriggers................................................ 943 14.4.15 Troubleshooting the crane control............................................. 945 General malfunctions............................................................. 946 Symbols in the error or information display areas................................. 946 Displays in the Error menu........................................................ 950 14.4.16 Malfunctions on the CraneSTAR system.......................................... 952 14.5 Emergency operations and programs.................................................... 953 14.5.1 Mechanical emergency activation for retracting................................. 954 Prior to the emergency activation, check.......................................... 954 Procedure......................................................................... 954 Mechanical emergency activation.................................................. 955 14.5.2 Telescoping emergency program.................................................. 957 Open the Emergency program submenu............................................... 957 Determining the type of error.................................................... 958 If there is an error on the length indicator...................................... 959 Tables for approaching the locking points......................................... 963 14.5.3 Entering the current telescoping............................................... 965 14.5.4 Emergency operation with the hand-held control................................. 967 Preparations...................................................................... 967 Pre-selecting a power unit........................................................ 968 Operating apowerunit............................................................ 968 Stopping movements............................................................... 969 Stopping movements in emergencies................................................. 970 Switching off theengine.......................................................... 970 14.6 Hydraulic emergency operation........................................................ 971 Switching over valves................................................................. 971 Releasing/ securing valves............................................................ 972 For lowering.......................................................................... 973 14.6.1 Performing emergency activation................................................ 975 14.6.2 After the emergency activation................................................. 975 14.6.3 Operating principle of emergency operation BGR 159............................. 976 14.6.4 Connecting/disconnecting hoses................................................. 977 Establishing connections.......................................................... 977 Disconnecting connections........................................................ 978 14.6.5 Switching emergency operation on/off........................................... 979 14.6.6 Establishing the hydraulic circuits required................................... 979 Switching over valves............................................................. 979 For lifting/ lowering............................................................. 981 For slewing....................................................................... 982 14.6.7 Performing emergency operation................................................. 983 Slewing........................................................................... 983 Derricking........................................................................ 984 Lifting/lowering.................................................................. 984 14.6.8 After emergency operation...................................................... 985 Switching off emergency operation................................................. 985 Switching over to crane operation................................................. 985 Disconnecting thehoses........................................................... 985 14.6.9 Emergency supply of another crane.............................................. 986 For emergency supply.............................................................. 986 After emergency supply............................................................ 986 15 Index...................................................................................... 989 A......................................................................................... 991 B......................................................................................... 991 C......................................................................................... 992 D......................................................................................... 995 E......................................................................................... 997 F......................................................................................... 998 H......................................................................................... 998 I......................................................................................... 999 L.........................................................................................1000 M.........................................................................................1000 O.........................................................................................1001 P.........................................................................................1002 R.........................................................................................1003 S.........................................................................................1004 T.........................................................................................1005 V.........................................................................................1007 W.........................................................................................1007
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